Orders filling system with cartridge dispenser

ABSTRACT

An automated ordering system has a gathering conveyor belt and a plurality of product dispenser onto the gathering conveyor belt, the plurality of product dispensers arrayed in a matrix in rows and columns wherein each row of product dispensers and each column of product dispensers share common control elements. The product dispensers are of cartridge type utilizing gravity to eject products from a cartridge suspended above the gathering conveyor belt onto the gathering conveyor belt. A universal product dispenser platform accepts a wide range of different sizes and shapes of cartridges storing products to be dispensed. The universal product platform provides support for an actuator for singulating products mounted to the cartridge.

This is a continuation of application Ser. No. 08/434,030 filed May 3,1995, now U.S. Pat. No. 5,551,822 which is a file wrapper continuationapplication of Ser. No. 08/177,140, which is now abandoned, filed Jan.4, 1994, now abandoned, which is a divisional of Ser. No. 08/115,247,filed Sep. 1, 1993, now U.S. Pat. No. 5,322,406, granted Jun. 21, 1994,which is a file wrapper continuation application of Ser. No. 07/884,863,now abandoned, filed Apr. 16, 1992, now abandoned, which is a filewrapper continuation application of Ser. No. 07/566,530, filed Aug. 13,1990, now abandoned.

TECHNICAL FIELD

The present invention relates to order filling systems and productdispensers for filling orders for products in less than case lotquantities, and in particular to automated systems and productdispensers for picking products at medium volume rates. BACKGROUND OFTHE INVENTION

Most often, a manufacturer of products packages a plurality of products,sometimes called a lot, into cases for storage and subsequent shippingto distributors. The quantity of products in the case is referred to asa case lot quantity. At some point during the distribution of theproduct, a manufacturer or a distributor may be required to break open acase for further distribution of the products in less than case lotquantities. Frequently, products in less than case lot quantities areassembled with other products pursuant to an order that includes morethan one product.

A distributor or manufacturer who supplies less than case lot quantitiesmust pick products from the cases, referred to as broken case orderpicking, before shipping an order that includes a selection of products.Filling an order for multiple products in less than case lot quantitiesrequires going to a case for each product, picking and counting thenumber of units of the product from the case, and assembling the pickedproducts to be shipped into a single container. These tasks have, in thepast been performed manually. People, though, are relatively slow andprone to pick or pull wrong products and incorrect quantities from thecases and may even forget to pull a particular product. Automation ofbroken case picking is, consequently, preferred in order to minimize thenumber of incorrectly filled orders and the costs resulting from pickingerrors.

Automated ordering systems (AOS) are available to automate the pickingprocess. In a typical AOS, a terminal operator receives an order andtypes it into the system on a keyboard as a part of a terminal coupledto a host computer. The host computer handles accounting and inventorycontrol functions for the distribution operation. The host computerprovides the order to a workstation for handling or editing. When theorder is ready to be executed, a central control computer as a part ofthe work station directs in real time the filling of the order.

An AOS is comprised, in essence, of a plurality of individual productdispensers stocked with different types products that are arrayed alongthe length of a gathering conveyor belt. In some systems there areliterally hundreds or thousands of different products and productdispensers. The gathering conveyor belt is constantly moving. Thecentral control computer segments or defines virtually, in memory, oneor more gathering conveyor belts into order zones, separated by bufferzones, in which are collected products for filling an order. As avirtual order zone for a particular order moves past a product dispenserstocking a selected product, the central control computer directs aprogrammable logic controller associated with that product dispenser tocause the product dispenser to dispense the ordered quantity of theproduct.

Product dispensers in an AOS singulate the products for counting--aproduct dispenser dispenses only one product at a time--and verifiesthat the products have been dispensed. Typically, associated with eachproduct dispenser is a photoelectric cell or some other means fordetecting a product to verify that a product is actually dispensed. Inorder to ensure that a product dispenser actually dispenses an orderedquantity of product into an order zone as it passes the dispenser, theproduct dispenser must be capable of rapidly ejecting products onto thegathering belt. To achieve rapid rates of dispensing, a force mustgenerally be applied to the product. Given that product dispensers mustsingulate and rapidly eject products, elaborate means for dispensing andmeans for controlling the dispenser are required, especially asthroughput of an AOS is increased.

Product dispensers must also address the problem of replenishing thestock of products in each dispenser. The stock in some productdispensers is replenished manually; others have elaborate automatedmeans for replenishing. Whatever method is chosen, a replenishing systemmust be provided, usually complicating the effort to achieve an optimumdesign of the product dispenser and sometimes demanding compromise.

Finally, the cost of automation limits the use of an AOS such has beendescribed to high volume products. In most broken case distributionoperations, about twenty percent of the different types of productsaccount for eighty percent of the total volume of products picked andshipped. There may be, for example, products handled by the distributionoperation that are picked only once a month. The return on investmentfor incorporating products picked only once a day, much less once amonth, rarely justifies automation. The high cost of an AOS, therefore,deters automation for most of the broken case operations.

Prior art product dispensers for an AOS are directed to high volumepicking, high volume being required to achieve a sufficiently highreturn on investment to justify automation. The prior art tends,therefore, to teach against automating lower volume products.Consequently, approaches to low volume picking do not utilize AOS thathave been described. Instead, the low volume approaches analogize tomanual picking. One such approach, called a "flying dutchman" utilizes asled mounted on a track beneath magazines holding products. The sledspeeds back and forth along the track picking with a mechanism on thesled products from the magazines and placing them on the sled, much likea person manually picking products. It has the advantage of requiring aminimal number of dispensing mechanisms, but at the expense of, amongother disadvantages, requiring a very sophisticated and expensivecontrol mechanism for moving the sled and picking mechanism. Anotherapproach is the use of robotic carts roaming the warehouse. It toosuffers from complicated controls.

SUMMARY OF THE INVENTION

Addressing primarily the problem of automating picking products on acost-effective basis, the invention is a medium volume automatedordering system (AOS-MV) and product dispenser for picking types ofproducts where the lower volume does not make it viable for automationutilizing prior art high volume AOS (AOS-HV). Contrary to the teachingsof prior art AOS-HV and other proposed approaches to the problem ofautomating medium volume picking, the present invention utilizes agathering conveyor belt for lower volume products and the same orsimilar central control computer and programmable logic controllers usedin AOS-HV. Indeed, an AOS-MV in accordance with the teachings of thepresent invention may be integrated into an AOS-HV system having thesame order management system, central control computer and productdispenser controllers. High volume gathering conveyor belts pick thehigh volume products required to fill an order and medium volumegathering conveyor belts, operating in parallel more or lesssynchronously with the higher volume belts, pick the medium volumeproducts identified in the order at approximately the same time. Anindex conveyor belt then collects all products for the order from allgathering conveyor belts as the orders appear (order zones on the beltsbeing delayed with respect to each of these to permit collecting in acommon tote) for transporting the order either to a manual picking areafor completing the order with very infrequently picked products, or to ashipping area if complete.

Unlike prior art AOS-HV, the present invention utilizes a matrixarrangement of product dispensers with means for controlling the"firing" of the product dispensers that minimize the number ofcomponents necessary for dispensing a product and verifying that theproduct has been dispensed, resulting in reduced system costs. Productdispensers for a gathering conveyor belt are formed into a "matrix" ofdispensers mounted in a row across a gathering conveyor belt at a heightabove the belt to permit dispensed products to pass freely. Multiplerows of product dispensers are mounted along the length of the gatheringbelt. This matrix arrangement has the advantage of permitting rows andcolumns of product dispensers to share common control elements, such asprogrammable logic controllers, relays and photoelectric cells forverification. Though sharing of control elements usually permits onlyone dispenser in a given row and column to be fired at a time, thepresent invention recognizes that, given the low quantities of productsto be dispensed, there is a low probability more than one productdispenser in any given row or column will be fired simultaneously.Consequently, the total number of components needed for the controlsystem is reduced.

The product dispenser for the present AOS-MV is also designed, unlikemost prior art product dispensers, to take special advantage of lowervolumes of products dispensed to reduce cost, as well as addressconcerns special to lower volume product dispensing. First, the meansfor singulating and dispensing a product is able to utilize gravityinstead of a powered delivery since quantities of a product dispensedinto any one order zone are small. Second, the product dispenser issmall and compact, permitting a closely packed configuration along agathering conveyor belt. Third, since these low volume products are notfrequently dispensed, a cartridge for holding the products also acts asa suitable storage container. These cartridges are adaptable to varioussized and shaped products. Fourth, a universal product dispenserplatform that is capable of holding a range of cartridges of differentsizes and shapes is mounted to a gathering conveyor belt.

Each cartridge has a mechanism for singulating the product storedtherein. Mounted to each platform is a universal actuating mechanism foractuating the mechanism for singulating. Fifth, replenishment is asimple manual operation. To further improve the replenishment process,and reduce the amount of time required for it, the cartridge is cantedto the nearest side of the gathering conveyor belt for easy access. Thegathering conveyor belt is also mounted low to the ground to facilitateaccess. The cartridge has an opening along its length so that a stack ofproducts is set in instead of being placed through an end one at a time.The cartridge is mounted to slide off the platform and be replaced witha previously filled cartridge. It may also be tilted back to permitaccess to the opening in the cartridge for refilling.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B are perspective views of an automated ordering system(AOS) having a plurality of product dispensing arranged in a matrixfashion.

FIG. 2 is schematized plan view of a warehouse having two AOS and anindex conveyor for collecting products from each AOS to complete anorder.

FIG. 3 is a block drawing and data path of a integrated automatedcontrol system for multiple AOS in a warehouse.

FIG. 4 is a matrix schematic of a controller for a plurality of productdispensers wherein a row of product dispensers are coupled to a commoncontrol element and share a common means for verifying dispensing of aproduct, and columns of product dispensers sharing a common controlelement.

FIGS. 5A and 5B are cross-sectional side views of a cartridge type ofproduct dispenser illustrating the process of dispensing a product.

FIG. 6 is an exploded perspective view of a cartridge and mounting for acartridge type of product dispenser.

FIGS. 7A and 7B are cross-sections taken along section lines A--A andB--B, respectively, in FIGS. 5A and 5B, respectively.

FIG. 8 is a cross-sectional elevational view of a medium volume AOS(AOS-MV) with a plurality of cartridge type product dispensers (withoutmeans for actuating shown) mounted in a row across a gathering conveyorbelt.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring now to FIG. 1A, there shown a perspective view of an automatedordering system for medium volume products (AOS-MV) 101. Suspended abovea gathering conveyor belt 103 are a plurality of product dispensers 105.Only a cartridge 107 for storing a product to be dispensed ontogathering conveyor belt 103 for a cartridge type product dispenser formedium volume products is illustrated. Each cartridge 107 indicates theposition of a product dispenser. Product dispenser cartridges 107 may beof different shapes and sizes, as shown, with only limited restrictionon the placement of the cartridge with respect to the conveyor belt orgathering conveyor belt 103 due to the cartridges size or shape. Productdispenser cartridges 107 store a plurality of different products (notshown) for dispensing.

The plurality of product dispensers 105 are arranged in a "matrix"fashion in rows and columns such that a particular product dispenser, ormore particularly its location, may be identified by an "x" and "y"coordinate system. Other means for dispensing may also be used,including high volume product dispensers, also arranged in a matrixfashion. Dashed line 109 indicates a row ("row" is chosen for notationpurposes only, as it may also be labeled a "column" if desired) ofproduct dispensers having a known location with respect to the directionof travel of gathering conveyor belt 103. In FIG. 1A, six productdispensers per row are shown. However there is no inherent limitation onthe number of product dispensers per row except by the spacerequirements imposed by the product dispensers. Further, there is nospecific requirement that each position on the row be occupied by aproduct dispenser. The plurality of product dispensers in the matrixalso forms columns along the length of the gathering conveyor belt 103,the number of columns equaling the number of product dispenser positionsin a row. Precise physical alignment of product dispensers in thecolumns is not required.

The matrix arrangement may also be utilized with high volume AOS(AOS-HV).

Gathering conveyor belt 103 is shown to have ribs 111 to preventproducts dispensed onto the conveyor 113 from rolling. Other methods ofcleating the conveyor belt well known in the art may also be employed.The gathering conveyor belt 103 is separated into defined order zones115 and buffer zones 117. An order zone 115 represents one order or apart of one order. Order zones need not be spaced apart at equaldistances. The order zones and buffer zones are not physically definedon the gathering belt 103 (an order zone is not defined by position ofthe ribs 111). The position and size of the order zones are definedvirtually in a central computer controller (not shown). The centralcomputer controller tracks the positions of the order zones 115 in realtime as each zone moves with the gathering conveyor belt 103. As anorder zone moves beneath a product dispenser 105 storing a product on anorder, the product dispenser dispenses the product into the order zone.Buffer zones 117 minimize the possibility of products from adjacentorder zones accidentally mixing.

Extending beneath each row of product dispensers, but above products onconveyor 113, is a beam of light 408 emitted from photo electric cell407 and reflected by reflector 409 back to a photo electric switch 407.

The gathering conveyor belt 103 is shown divided into front end 103A anda terminating end 103B.

Referring now to FIG. 1B, the terminating end 103B of gathering conveyorbelt 103 transfers products in an order zone onto a conveyor belt 131which acts as a transition between gathering conveyor belt 103 and indexconveyor 137. Transition conveyor belt 131 transports the products fromthe gathering conveyor belt 103 to slide 135. Slide 135 directs productsinto a tote 133 that is positioned beneath slide 135 by index conveyor137.

Referring now to FIG. 2, there is shown a plan view schematicrepresentation of the integration of AOS-MV 101 into an automatedpicking operation with an AOS 201, which is either an AOS-MV or highvolume AOS (AOS-HV). AOS-MV 101 and AOS 201 are shown inrepresentational format. In a warehouse operation, there will likely bemultiple AOS-MV lines and multiple AOS-HV lines terminating in one ormore index conveyors 137. To fill an order, products may be dispensedfrom more than one AOS line. Totes 135 and index conveyor 137 act as ameans to gather or to collect portions of the order from each of the AOSdispensing products to fill the order. The AOS-MV 101 may be operated insynchronization with other AOS-MV as well as AOS-HV so that all portionsof an order filled by an AOS can be collected in one tote 135 on indexconveyor 137. Tote 135 on index conveyor 137 collects, in the mannerdescribed in connection with FIG. 1B, an order from the AOS-MV 101. Tote135 is moved along conveyor 137 to the second AOS 201 which is either ahigh volume or a medium volume AOS that fills another portion of theorder. In operation, tote 135 appears at the end of a AOS just in timeto collect from the products deposited onto buffer conveyor belt 131(FIG. 1B) before the next order zone is deposited.

After one or more totes 135 collects all the portions of an order fromall the AOS in the warehouse, tote 135 proceeds to gate 203 on indexconveyor 137. If some of the ordered products must be picked manually,tote 135 is diverted to conveyor 215 which takes the tote 135 to amanual pick area. If the order is filled, gate 203 permits tote tocontinue on index conveyor 137 to a shipping area.

Other means of collecting portions of the order from each AOS may beused instead of totes, such as compartmentalized conveyor belts androbotic carts.

Referring now to FIG. 3, there is shown a schematic diagram of thecontrol system for a multiple-AOS system. Orders received by thedistributor are entered into and stored in host computer 301. Accountingand inventory control functions reside in the host computer 301. Thehost computer provides the order to an operator position work station303 for editing if desired. The operator position work stationdetermines when the order is to be released to the AOS for picking.Connected to the operator position work station 303 is an order printer305 on which a hard copy of the order may be printed.

A released order is received from the operator position work station 303by a central control computer 307 on bus 309. Central control computer307 controls the real-time operation of all the AOS-MV, AOS-HV and indexconveyors as well as other automated functions in the warehouse. Centralcontrol computer 307 creates or defines on the appropriate AOS thenecessary order zones to fill the order and keeps track in real-time ofthe position of each order zone 115 on each gathering conveyor belt 103(FIG. 1) of each AOS. This computer also issues the address of a productdispenser to trigger a firing signal at such time as to cause a productdispenser stocking an ordered product to fire and to dispense or releasethe product onto the gathering conveyor belt as an order zone passesbeneath the row in which the product dispenser is located.

Network buses 311, 337 and 338 links the central control computer 307 toeach of the AOS in a warehouse. Coupled to each network bus are aplurality of product dispenser controllers 313 to which are coupledproduct dispensers 105.

A programmable logic controller 315 as a part of a product dispensercontroller 313, after receipt of a firing or dispense signal fromcentral control computer 307 on network bus 311, issues a firstactuating signal on a line bus 317 to a relay bank 319, and a secondactuating signal on a line bus 321 to a relay bank 323. Relay bank 319has "M" relays and bus 317 has "M" relay control lines, one for eachrelay. Relays in relay bank 319 couple to +VDC solenoids or otheractuating means, such as a servo-motor, of product dispensers (105 ofFIG. 1A) intercoupled in columns, each column of product dispensersbeing coupled to a common relay in relay bank 319, through lines 325.Relay bank 323 has "N" number of relays, and bus 321 has "N" number ofrelay control lines. Relays in relay bank 323 couple to ground solenoidsor other actuating means of product dispensers (105 in FIG. 1A)intercoupled in rows, each row of product dispenser being coupled to acommon relay in relay bank 323, by lines 327. In effect, when a relay inrelay bank 323 and a relay in relay bank 319 are simultaneouslyenergized, a power circuit is completed for energizing a solenoid orother means for actuating of a product dispenser common to both a columnof product dispensers coupled to the relay in relay bank 319 and a rowof product dispensers coupled to the relay in bank 323. A detailedschematic of a product dispenser controller is described in FIG. 4.

The programmable logic controller 315 also receives input signals on bus331 from photoelectric cells that verify that a product has been droppedonto gathering conveyor belt 103 (FIG. 1).

The product dispenser controller 313 has a limited number of outputs andinputs available. As one AOS-MV or AOS-HV may have many productdispensers associated with it, more than one product dispensercontroller 313 may be required to control an AOS.

Central control computer 307 also controls an AOS-MV lines by means of anetwork bus 337. Network bus 338 provides control signals from centralcontrol computer 307 to additional AOS-MV. The operation of each of theproduct dispenser controllers 313 is identical to that described abovein connection with data highway 311. As indicated, more than one productdispenser controller 313 may be required to control all the productdispensers on a single AOS-MV.

Central control computer 307 also receives signals indicatingverification for dispensed products on network buses 311, 337 and 338from all the product dispenser controllers 313. If the central controlcomputer 307 fails to receive the verification that the product has beendispensed as directed, the computer 307 advises operator position workstation 303 on line 345 that a product has failed to be dispensed.Operator position work station 303 then issues appropriate instructionsto personel on hand in the warehouse for completing the order anddirecting actions necessary to correct the problem, such as replenishingthe product dispenser with the products. Central control computer 307also controls index conveyor 137 (FIGS. 1B and 2) through a programmablelogic controller (PLC) 347 via bus 349. Other automated functions in thewarehouse may also be controlled by central control computer 307 throughlines 351, such as operating gate 203 (FIG. 2).

Referring now to FIG. 4, there is shown a schematic representation of amatrix 405 of product dispensers 403 (product dispenser 105 in FIG. 1A).Bus 317 (FIG. 3) is comprised of relay control lines labeled Y₁ to Y_(M)where M is the number of product dispensers in a column. Each relaycontrol line Y is connected to a relay 401 in the relay bank 319. Bus321 (FIG. 3) is also comprised of relay control lines labeled X₁ toX_(N), where N is the number of rows of product dispensers controlled bya product dispenser controller 313 (FIG. 3). Each relay control line isconnected to a relay 401 in relay bank 323.

Product dispensers 403 are arrayed in a matrix 405. The lines extendingfrom relays 401 in relay bank 319 interconnect columns of productdispensers 403 in the matrix 405, and represent coupling of each productdispenser 403 in a column (a column of intercoupled means fordispensing) to a common control element, namely a relay 401 in relaybank 319. Similarly, the lines from relays 401 in the relay bank 323interconnect rows of product dispensers 403 in the matrix 405, andrepresent the coupling of each product dispenser 403 in a row (a row ofintercoupled means for dispensing) to a common control element, namely arelay 401 in relay bank 323.

To activate or cause to dispense a product dispenser coupled to them^(th) and n^(th) relays 401, a control or actuating signal, on relaycontrol line Y_(m) energizes the m^(th) relay in the bank of relays 319thereby enabling each product dispenser 403 in the column coupled to them^(th) relay 401 in relay bank 319 to dispense by connecting each to apositive voltage +VDC. A second control or actuating signal fromprogrammable logic controller 315 recieved on a relay control line X_(n)on bus 321 energizes the n^(th) relay 401 in relay bank 323 therebyenabling each product dispenser 403 in a row coupled to the n^(th) relayin relay bank 323 to dispense by coupling each to ground. Typically the,programmable logic controller 315 (FIG. 3) rapidly sweeps--"turnson"--each relay 401 in relay bank 319 to insure that only one productdispenser 403 in a row of intercoupled product dispensers is enabled todispense a product. During a sweep, one or more rows of intercoupledproduct dispensers are turned on by actuating one or more relays inrelay bank 323 thereby completing one or more control circuits foractuating the dispensing of products.

Each row of product dispenser 403 share a means for verifying. Aphotoelectric switch 407 emits a beam of light 408 toward reflector 409and detects the reflected light. The beam of light 408 is positioned sothat a product dispensed from any of the product dispensers 403 in a rowbreaks the beam of light, and thereby verifies that a product from therow has been dispensed. Only one photoelectric cell 407 or other meansfor verifying is required per row of product dispensers, as only oneproduct dispenser per row is permitted to be actuated at one time. Eachphotoelectric cell 407 has an output line as a part of V₁ --V_(n) on bus331 that provides a verification signal to programmable logic controller315 (FIG. 3).

Referring now to FIGS. 5A and 5B, there is shown a side view of acartridge type product dispenser 500. A cartridge slide rail 501 havinga slot 502, is mounted to cross rail 503. Attached to the cartridgeslide rail 501 through a support bracket 505 is a rotary solenoid 507.Rotary solenoid 507 is a reciprocating rotary solenoid and is a type ofelectromechanical means for actuating product dispensers. Coupled to anoutput shaft 509 of rotary solenoid 507 is an actuating arm having afirst member 511A extending perpendicularly from and connected to shaft509, and a roller member 511B that extends perpendicularly from the endof first member 511A and engages stop gate 513.

Stop gate 513 is axially mounted on a shaft 517 and secured to the shaft517 by a set screw 519. Shaft 517 is mounted to interior cartridge shell521 with axial mounts 523 that permit shaft 517 to rotate. Located atone end of shaft 517 a spring 525 biases the position of the shaft in afirst, unactuated position. Attached to the other end of shaft 517 isdispense gate 527. When the shaft 507 is in the first position, the gate527 extends in a "closed" position across opening 529 in cartridge 530.Gate 527 holds a product 533 in the position indicated.

Opposite from the solenoid 507 a stripper 535 extends through outercartridge shell 537 into cavity 531. The stripper 535 functions to placea restriction in the cavity 531 to provide just enough space to permitproduct 538 to pass. Stripper 535 is slidably mounted to adjustablebrackets 539 that are mounted to outer cartridge shell 537. Rotatingarms 541 coupled to adjustable brackets 539 and a slot 542 in thestripper 535 permit adjusting the position of stripper 535 in order toaccommodate products of different shapes (circular, square andrectangular) widths and lengths. The position of stop gate 513 must alsobe adjusted when the position of stripper 535 is adjusted for differentlength products by releasing set screw 519 and a sliding stop gate 513along shaft 517 to a position opposite of the stripper 535.

Now referring specifically to FIG. 5B, product 533 is dispensed fromcartridge cavity 531 upon actuation of rotating solenoid 507 byapplication of power to the solenoid. Upon actuation, rotating solenoid507 engages stop gate 513 and causes it to rotate with the shaft 517 andextend through opening 543 into inner cartridge shell 521 (see FIG. 6for details of the inner cartridge shell 521 and the outer cartridgeshell 537). Rotation of stop gate 513 rotate the shaft 517 to a second,actuated position, thereby causing dispense gate 527 to swing open topermit product 533 to fall through opening 529 under the influence ofgravity. When rotated into the second position, stop gate 513 contactsproduct 533 to ensure that it falls through opening 529. In the secondposition, stop gate 513 acts in combination with stripper 535 to preventproduct 538 from falling into the space in cartridge cavity 531previously occupied by product 533. In this manner, cartridge productdispenser 500 singulates products.

When the power that actuated the solenoid 507 is disconnected, spring525 rotates shaft 517 and returns it to the first, unactuated position.Stop gate 513 is retracted and the cavity 531 is closed by extendingdispense gate 527 over opening 529, as illustrated in FIG. 5A. At thispoint, product 538 falls into the position previously occupied byproduct 533 and is ready for dispensing, and a product (not shown)behind product 538 in a stack of products (not shown) stored withincartridge 530 falls into the position occupied by product 538.

Turning now to FIG. 6, a plurality of cartridge support rails 501 may besecured to cross rail 503 by use of bolts (not shown) inserted throughholes 601.

Cartridge 530 is shown in an exploded view as including the interiorshell 521, having an inner surface 607 on which a stack of products 533,538 and 609 rest, and the outer shell 537. Interior shell 521 and outershell 537 are assembled into cartridge 530 by inserting interior shell521 through opening 529 defined in the end of outer shell 537. A slot603 in the outer shell 537 permits opening 529 to be enlargedsufficiently to permit cartridge mounts 614 to be inserted throughopening 529. The interior and outer shells 521 and 537 are formed ofmolded plastic.

The cartridge 530 as assembled (shown in FIG. 5) is opened to receiveproducts by rotating outer shell 537 relative to interior shell 521 suchthat opening 605 is aligned with the inner surface 607. Exposing innersurface 607 permits products 533, 537 and 609 to be inserted intocartridge 530. To close the cartridge, the outer shell 537 is rotated inthe opposite direction, thus providing a suitable storage means forproducts 533, 537 and 609.

As shown in FIG. 6, the stripper 535 is inserted through slot 603 andsecured to mounts 539 with bolts 611 and wing nuts 613.

The assembled cartridge 530 is slidably mounted to cartridge supportrail 501 with bolts 615 threaded into mounts 614 through slot 502defined in cartridge slide rail 501. A key hole 619 is provided largeenough to permit passage of the head of bolt 615 for assembly andremoval of the cartridge 530.

Referring now to FIG. 7A, there is shown a cross-section taken alongsection 7A--7A of FIG. 5 illustrating the method of singulation employedby cartridge type dispenser 500. In a first, unactuated position thedispense gate 527, shown in phantom, extends across the open end 529(FIG. 5A) of cavity 531 for holding product 533 (shown in crosssection). Stop cam 513 is in a retracted position and does not extendthrough opening 543 into cartridge cavity 531. Rotary solenoid 507 isnot actuated, actuating arm 511A is in a retracted position.

Referring now to FIG. 7B, there is shown a cross-section taken alongsection line 7B--7B of FIG. 5B, when power is applied to rotary solenoid507 it causes actuating arm 511A to move into an actuated position.Roller arm 511B applies a force generated by actuation of rotarysolenoid 507 to stop gate 513 thereby causing the stop gate to rotateand extend through opening 543 into cartridge cavity 531. Application ofa force by rotary solenoid 507 to stop cam 513 also causes shaft 517 torotate into a second, actuated position. Rotation of the shaft 517 intoa second position rotates the dispense gate 527 into an open positionand it now does not extend across opening 529 (FIG. 5) of cartridgecavity 531. This permits product 533 (not shown) to fall out of opening529. The stop gate 513 now holds product 538, the product stacked on topof product 533 (see FIG. 5) and prevents it from falling through opening529 (FIG. 5) while the dispense gate 527 is open. The describedoperation singulates the products stored in cartridge 530 fordispensing.

Referring now to FIG. 8, there is a cross-sectional elevational view ofan AOS-MV utilizing cartridge type product dispensers 500 (FIG. 5)arrayed in a row across a gathering conveyor belt 801. Conveyor sidefences 807, one deployed on each side of gathering conveyor belt 801,mounted to supports 805 prevent products from falling off the side ofthe conveyor belt. Conveyor side fences 807 also provides supports formounting cross rails 503 across the gathering conveyor belt 801. Aphotoelectric cell 407 is mounted to one conveyor side fence 807. Alight beam 408 emitted by photoelectric cell 407 extends acrossgathering conveyor belt 801 to reflector 409 mounted on the otherconveyor side fence 807. The photoelectric cell 407 and reflector 409are positioned immediately below the row of cartridge dispensers 500such that a product dispensed by one of the product dispensers in therow interrupts light beam 409 as it falls to gathering conveyor belt801.

A plurality of cartridge slide rails 501 are mounted to cross rail 503at a predetermined angle such that each cartridges 530 leans toward theside of gathering conveyor belt 801. Mounting the cartridge slide rails501 at an angle permits easier access to cartridges 530 for replenishingwith products.

Cartridge slide rail 501, together with solenoid 507 and actuating arm511 (not shown, see FIG. 5), as well as cross rail 503, form a universalproduct dispenser platform, capable of accepting a wide range of sizesand shapes of cartridges 530. Though cartridges 530 are shown in acylindrical shape having a fixed diameter, cartridges in differentshapes and sizes, for example rectangles, are mountable on universalproduct mount 811 for dispensing of products stored therein.

Cartridges 500 are slidably mounted to cartridge slide rails 501,thereby permitting a cartridge 530 to be slid into an extended position,indicated in phantom, for easier on-line replenishing. When extended, acartridge may be opened and replenished as described in connection withFIG. 6. Mounting the slide rails 501 tilted toward the nearest side ofgathering conveyor belt 801 also facilitates removal of empty cartridges530 and replacement with cartridges prestocked with product. A cartridgeis held in an extended position by placing a bolt 615 into the key hole619.

The invention has been described in connection with a preferredembodiment. This description is not intended to limit the scope of theinvention to the particular form set forth. On the contrary, it isintended to cover such alternatives, modifications, and equivalences asmay be included within the spirit and scope of the invention as definedin the appended claims.

I claim:
 1. An automated order gathering system comprising:an indexconveyor; a plurality of gathering belts, each of said gathering beltshaving a downstream output end to deliver products onto said indexconveyor; at least one product dispenser associated with each gatheringbelt for dispensing one or more products onto said associated gatheringbelt; and means for controlling the delivery of one or more productsinto a predetermined area of said index conveyor, said means forcontrolling including: means for selectively actuating one or more ofsaid product dispensers to dispense product onto the associatedgathering belt; and means for selective controlling each of saidgathering belts to deliver products in identifiable orders to said indexconveyor.
 2. An automated order gathering system as set forth in claim 1including at least one tote positioned on said index conveyor to receiveproducts delivered from said plurality of gathering belts.
 3. Anautomated order gathering system as set forth in claim 1 wherein saidindex conveyor comprises a shipping section and a manual pick sectionand further including a divert gate movable between the shipping sectionand the manual pick section to divert an identifiable order on the indexconveyor to the manual pick section.
 4. An automated order gatheringsystem as set forth in claim 1 wherein said means for controllingfurther includes means for defining virtual order zones and buffer zoneson each of said gathering belts.
 5. An automated order gathering system,comprising:an index conveyor; at least one transition conveyor belthaving a downstream output end for delivering products onto said indexconveyor; a plurality of gathering belts, each having a downstreamoutput end for product delivery, at least one of said gathering beltsassociated with at least one of said transition conveyor belts, each ofsaid gathering belts delivering products directly to said index conveyoror to an associated transition conveyor belt; at least one productdispenser associated with each gathering belt for dispensing one or moreproducts onto said associated gathering belt; and means for controllingthe delivery of one or more products onto a predetermined area on saidindex conveyor, said means for controlling including: means forselectively actuating one or more of said product dispensers to dispenseproduct onto the associated gathering belts; and means for selectivelycontrolling each of said gathering belts and each of said transitionconveyor belts to deliver products in identifiable orders to said indexconveyor.
 6. An automated order gathering system as set forth in claim 5including at least one tote positioned on said index conveyor to receiveproducts delivered from said plurality of gathering belts.
 7. Anautomated order gathering system as set forth in claim 5 wherein saidindex conveyor comprises a shipping section and a manual pick sectionand further including a divert gate movable between the shipping sectionand the manual pick section to divert an identifiable order on the indexconveyor onto the manual pick section.
 8. An automated order gatheringsystem as set forth in claim 5 wherein said means for controllingfurther includes means for defining virtual order zones and buffer zoneson each of said gathering belts.
 9. An automated order gathering systemas set forth in claim 5 where each of said at least one transitionconveyor belts includes order zones for separating identifiable ordersfrom the associated gathering belt onto said index conveyor.
 10. Anautomated order gathering system comprising:an index conveyor; aplurality of gathering belts, each having a downstream output end fordelivery of products onto said index conveyors; at least one productdispenser associated with each gathering belt for dispensing one or moreproducts onto said associated gathering belt, at least one of saidproduct dispensers including: a plurality of storage means arrayed in acolumn by row matrix, said storage means holding products of differentshapes and sizes to be selectively dispensed onto an associatedgathering belt; a plurality of means for dispensing products onto saidassociated gathering belt, each means for dispensing coupled to acorresponding row and column of the storage means matrix; first meansfor simultaneously actuating each of the means for dispensing coupled toeach of the storage means in a selected column; second means foractuating one means for dispensing per row at a time in one or more rowsof the matrix to dispense products onto said associated gathering beltfor multiple rows associated with a single column; and means forcontrolling the delivery of one or more products onto a predeterminedarea on said index conveyor, said means for controlling including: meansfor selectively actuating one or more of said product dispensers todispense products onto the associated gathering belt; and means forselectively controlling each of said gathering belts to deliver productsin identifiable orders to said index conveyor.
 11. An automated ordergathering system as set forth in claim 10 including at least one totepositioned on said index conveyor to receive products delivered fromsaid plurality of gathering belts.
 12. An automated order gatheringsystem as set forth in claim 10 wherein said index conveyor comprises ashipping section and a manual pick section and further including adivert gate movable between the shipping section and the manual picksection to divert an identifiable order on the index conveyor onto themanual pick section.
 13. An automated order gathering system as setforth in claim 10 wherein said means for controlling further includesmeans for defining virtual order zones and buffer zones on each of saidgathering belts.
 14. An automated order dispensing system comprising:afirst conveyor belt; a first plurality of product dispensers fordispensing products onto the first conveyor belt arrayed in a matrixhaving at least one column and at least one row; a first relay connectedto each product dispenser in a row and a second relay connected to eachproduct dispenser in a column, such that actuation of the first relayand the second relay simultaneously causes the product dispenser locatedin both a first row and a first column to dispense a product onto thefirst conveyor belt; a first order zone on the first conveyor belt ontowhich a product dispenser dispenses an ordered product; a secondconveyor belt; a second plurality of product dispensers for dispensingproducts onto the second conveyor belt arrayed in a matrix having atleast one column and at least one row; a third relay connected to eachproduct dispenser in a row and a fourth relay connected to each productdispenser in a column, such that actuation of the third relay and thefourth relay simultaneously causes the product dispenser located in botha first row and a first column to dispense a product onto the secondconveyor belt; a second order zone on the second conveyor belt intowhich the second plurality of product dispensers dispenses an orderedproduct; and means for collecting a third order zone into which thefirst and second conveyor belts deposit the ordered products.